Electrical connector and assembly thereof



Aug. 24, 1965 R. J. KlNKAlD ELECTRICAL CONNECTOR AND ASSEMBLY THEREOF 5 Sheets-Sheet 1 Filed Sept. 26, 1963 INVENTOR. R0502? I). KlNKmo Aug. 24, 1965 R. J. KINKAID ELECTRICAL CONNECTOR AND ASSEMBLY THEREOF 5 Sheets-Sheet 2 Filed Sept. 26, 1965 INVENTOR. Eoaaa'r I QNKPM) Aug. 24, 1965 R. J. KINKAID ELECTRICAL CONNECTOR AND ASSEMBLY THEREOF 5 Sheets-Sheet 3 Filed Sept. 26, 1963 INVENTOR. ROBERT J. Nu Kmu Aug. 24, 1965 R. J. KlNKAlD ELECTRICAL CONNECTOR AND ASSEMBLY THEREOF 5 Sheets-Sheet 4 Filed Sept. 26, 1963 INVENTOR. Poesm T \/\\NKR\D BY Aug. 24, 1965 R. J. KINKAID 3,202,954 ELECTRICAL CONNECTOR AND ASSEMBLY THEREOF Filed Sept. 26, 1963 5 Sheets-Sheet 5 LHL INVENTOR. PosiRT (I Kuwmo United States Patent Ofiice 3,292,954 Patented Aug. 24, 1965 3,202,954 ELECTRICAL CQNNEUTOR AND ASSEMBLY TIEREOF Robert .I. Kinkaid, New Cumberland, Pa, assig'nor to A Incorporated, Harrisburg, Pa. Filed Sept. 26, 1963, Ser. No. 311,700 13 Ciaims. (Cl. 339-47 This invention is directed to a hermaphroditic contact assembly, wherein multiple contact surfaces are provided therebetween which have flexibility to ensure excellent and positive contact along substantially the entirety of the contact surfaces.

In the construction of contact assemblies having multiple contact surfaces, a problem has consistently confronted the construction thereof which is to provide excellent, firm and positive contact therebetween to ensure good electrical connection which is important in the efiicient operation of electrical and electronic apparatus utilizing same. Heretofore, there has been utilized a contact assembly having multiple contact surfaces wherein the assembly consists of at least two identical contact members, each disposed in contact holders adapted to securely engage one another to provide frictional engagement between the contact members. Each contact member is disposed in each contact holder 90 with respect to the contact member in the other contact holder. The contact arms of each contact member have a point of flexion toward each other adjacent the base portion of the contact members, thereby providing only a single point of flexion for each contact arm. With only a single point of flexion, the engagement between contact surfaces of the contact arms is reduced and after repeated use, i.e., insertion, removal and reinsertion, the flexibility of the contact arms tends to decrease, thereby substantially reducing the engagement between the contact arms. Reduction of the flexibility can be overcome by increasing the amount of material at the point of fiexion, but this is impractical and uneconomical.

Moreover, since there is only one point of fiexion for each contact arm, the points of engagement between the contact arms of intermeshing similar contact members is reduced which subjects the contact members to discontinuous engagement if a member containing such contact assembly undergoes violent vibration effects, such as the buifeting of an aircraft or such similar vibration shocks.

In addition, the contact arms of the contact member engage the contact holder in which they are disposed,

V thereby aiding in the flexibility of the contact arms. However, since most of the contact holders are made from plastic material, this can undergo creep, thereby causing discontinuity between the Contact arms to occur.

It is an object of the present invention to provide a hermaphroditic contact assembly which provides multiple contact surfaces in excellent, firm and positive engagement.

Another object of the present invention is to provide a hermaphroditic contact assembly wherein the contact arms of each contact member engage each other substantially along the entirety thereof.

A further object of the present invention is to provide a hermaphroditic contact assembly in which the flexibility of the contact arms of each contact member thereof is parallel to the longitudinal axis of the base portion of the contact members.

An additional object of the present invention is to provide a hermaphroditic contact assembly wherein the engagement between each contact member is always continuous, and which can be utilized in various electrical and electronic applications.

A still further object of the present invention is to provide a quick connectable and detachable hermaphroditic contact assembly wherein each contact member readily connects with a complementary contact member.

Another object of the present invention is to provide a hermaphroditic contact assembly that is easily and economically produced, which is sturdy in construction and which is highly efficient in operation.

Other objects of the present invention will occur during the following detailed description of the present invention when read in conjunction with the accompanying drawings, in which:

FIGURE 1 is a plan View showing the contact members prior to engagement;

FIGURES 2, 3 and 4 are similar to FIGURE 1, but show the contact members at the point of engagement, almost in complete engagement and full engagement, respectively;

FIGURE 5 is a sectional view taken along the lines 55 of FIGURE 4;

FIGURE 6 is a perspective view of one of the contact members crimped onto a conductor means;

FIGURE 7 is a fragmentary, sectional, exploded view showing the present invent-ion when used in conjunction with a printed circuit board as an edge connector;

FIGURE 8 is a fragmentary, perspective, exploded, sectional view showing a right-angle connection of printed circuit boards utilizing the present invention;

FIGURE 8a is a part-sectional view taken on the lines AA of FIGURE 8;

FIGURE 9 is a fragmentary, perspective, exploded sectional view showing a housing for the contact members of the present invention and complementary contact members mounted on a printed circuit board;

FIGURES 9a and 9b are a part-sectional, and a bottom plan view, respectively, of the housing of FIGURE 9;

FIGURE 10 is a part-sectional view of permanent splice utilizing the present invention;

FIGURE 11 is a part-elevational view showing the present invention being utilized to provide a point-to-point connection on a plugboard;

FIGURES 12 and 13 show plan views of an embodiment of the contact assembly at the point of and completely in engagement, respectively;

FIGURE 14 is an exploded view of a connector block for the contact assembly of FIGURES 12 and 13;

FIGURE 15 is a sectional view of the connector block .of FIGURE 14 assembled and mounted on a panel; and

'URES'1-5, a hermaphroditic contact assembly 1 comprising contact members 2,. 3. Each contact member 2 is identical to the other contact member 3, which is an important feature in the manufacturing process since .dissimilar contact members do not have to be made. Each contact member 2, 3 has a base portion 4 which interconnects contact arms 5 and 6, each of which has a V-shape, cross-sectional configuration to lend strength thereto. If, desired, the cross-sectional configuration of arms 5 and 6 can be made into any other suitable configuration. As can be discerned, contact arms 5 and 6 extend from base portion 4 and face each other with the bottom of the V-shape opposing one another: The ends of the contact arms have a part-spherical configuration so that the contact arms of each contact member can readily engage each other.

The base portion 4 is integrally connected to contact arms 5 and 6 to thereby form a channel portion 7 and, in addition, is a spring member providing arms 5 and 6 with flexibility which is parallel with respect to the longitudinal axis of the contact member, i.e., the contact arm? i and 6 are resiliently biased toward each other so that he arms are almost in engagement with each other and, is can be seen from FIGURE 1, they taper slightly tovard each other toward the part-spherical ends thereof.

Thus, base portion 4 provides a major bending axis tbOllt which contact arms 5 and 6 bend toward and [way from each other, as well as minor bending axes at ight angles with respect to the major bending axis about vhich the contact arms bend upon the insertion of one :ontact member into a complementary contact member.

Contact arms 5 and 6 are about twice the length of use portion 4 but can be any suitable length depending men the application; however, in any event, arms 5 and 3 engage a large portion of corresponding contact arms :xtending from the base portion of a complementary con :act member as shown in FIGURE 4.

In assembly, contact members 2 and 3 are disposed at 'ight angles with respect to each other, such that base )ortions 4 of each contact member are normal to one an- )ther as shown in FIGURES 1-6. The contact members are intermeshed until the forward sections of base por- :ions 4 abut against each other (see FIGURE 4) thereby lefining limit means. As can be observed, the contact arms provide resilient guide members on the inner sides :hereof, along which the contact arms of each contact nember engage each other and one contact arm of each :ontact member is disposed in the channel portion 7 hereof.

Thus, the resilience applied to contact arms 5 and 6 3y base portion 4, and the tapered disposiiton of the con- :act arms, provide a hermaphoditic contact assembly in which the contact arms of each contact member engage one another along substantially the entirety thereof to provide an excellent, firm and positive engagement.

In FIGURE 6 there is shown a contact member containing a ferrule portion 8, which is crimped onto the and of conductor means 9 and the insulation thereof so as :0 make electrical and mechanical engagement therewith by cold-forging techniques conventional in the art, such as disclosed by US. Patent No. 2,600,012. Of course; :onductor means 9 can be secured to the contact member in any other suitable manner.

FIGURES 79 show the contact assembly in conjunction with a printed circuit board.

In FIGURE 7, there is shown a printed circuit board 10 showing a printed circuit 11 disposed thereon. Contact member 12, which is similar to the contact members described in FIGURES 15,-has extensions 13 and 14 extending from base portion 12' of contact member 12. As can be seen, extensions 13 and 14 extend through holes 15 of board 10, and have portions 13' and 14' which securely engage printed circuit 11 to make electrical and mechanical connection therewith by clinching and soldering, or in any other suitable manner.

A housing member 16 has an aperture 17 disposed therein, in which a contact member 2', similar to that shown in FIGURE 6, is securely mounted. While only one contact member is shown on printed circuit board 10 and in housing 16, it is to be understood that any number of contact members 12 corresponding to the number of printed circuits are mounted on board 10, and housing 16 has a corresponding number of apertures 17 containing contact members securely mounted therein but at right angles with respect to the disposition of contact members 12.

An opening 18 is disposed in housing 16 and the end portion of board 10 is insertable therein when the contact members of housing 16 engage contact members 12 of board 10 in a manner illustrated in FIGURE 4.

FIGURE 8 shows a printed circuit board 10' similar to that shown in FIGURE 7, but disposed substantially at right angles with respect to each other. A stabilizing and mounting strip 19 is securely mounted on lower board 10' by means of rivets 20 or such similar securing means. Disposed in strip 19 are cavities 21 through ber 2".

which contact members 22 extend. As shown in FIG- URE 8a, contact members 22 are similar to contact member 12 of FIGURE 7, except that only one extension 23 having a tubular cross-section extends from base portion 22 which engages a hole in board 10', and the portion 23' which emerges from the bottom surface is flattened to provide laterally-extending flanges thereby securing contact member 22 therein. Each cavity 21 has a recess 21' extending away from the contact arms of contact member 22.

The upper printed circuit board 10' of FIGURE 8 has contact members 12a similar to those disclosed in FIG- URE 7.

As can be seen, contact members 22 and 12a are arranged normal .to each other so that when contact members 12a engage contact members 22, one contact arm of each contact member is disposed in the channel portion thereof and the other arm of each contact member 12a is disposed in recess 21'.

While FIGURE 8 illustrates two printed circuit boards 10 connected together at right angles by means of the contact assembly consisting of contact members 12a and 22, a parallel connection between printed boards can be effected by mounting a stabilizing and mounting strip 19 on both pn'nted circuit boards. Of course, the contact members in one strip will have to be disposed at right angles with respect to the contact members in the other strip. It should also be pointed out that only one strip 19 need be utilized, since the contact members shown in FIGURE 8a can be inserted in one printed circuit board without the use of a strip.

FIGURE 9 shows a stabilizing and mounting strip 19' having contact members 22 mounted on a printed circuit board 10" in the manner illustrated in FIGURE 8. Disposed above strip 19' is a housing 24 having recesses 25 disposed therein. Contact members 2", similar to those shown in FIGURE 6, are securely mounted in recesses 25 (see FIGURES 9a and 9b) and a housing cover 26 is disposed in channels 27 in housing 24 to completely encase the contact members. Each recess 25 has a shoulder 28 against which the forward part of base portion 4" engages to limit the inward movement of contact mem- Also disposed in each recess 25 is a flange 29 against which the lower portion of the contact arms opposite base portion 4" engage, and another flange 30 opposite flange 29 biases ferrule portion 8" toward flange 29 so that the contact arms remain in engagement therewith to prevent rearward movement of the contact member when it is intermeshed with a corresponding contact member 22 of FIGURE 9, as well as to prevent accidental removal of the contact member upon force being applied to conductor 9".

In assembly, housing cover 26 is removed from housing 24 and contact members 2" are inserted in recesses 25, then cover 26 is inserted in channels 27 and main tained in place by a snap lock or other suitable means.

Housing 24 also has a longitudinal recess 30 in the bottom which corresponds to the configuration of strip 19, so that strip 19 is housed within recess 30 upon the contact members 2" thereof engaging contact members 22'.

Extensions 31 extend from the ends of housing 24 and each extension has a hole 32 therethrough which coincides with an aperture 33 in printed circuit board 10" in order that securing means can be inserted therethrough to secure the housing 24 onto the printed circuit board. Of course, any suitable securing means to secure housing 24 onto the printed circuit board can be utilized.

FIGURE 10 shows two contact members 2a, 3a, similar to that shown in FIGURE 6, which are in firm mechanical and electrical engagement as a contact assembly.

H Conductors 9a are secured to each contact member by ferrules 8a. A heat-shrinkable sleeving 34 of insulating material is disposed over intermeshing contact members 2a, 3a, and heat is applied thereto to cause sleeving 34 to tightly engage the contact assembly and conductors thereof, thereby forming a permanent splice.

FIGURE 11 shows conductor means 35 of any desired length having connected to each end thereof contact members 2b to form a jumper member. Mounted in plugboard 36 are contact members 37 similar to those shown in FIGURE 8a or FIGURE 7. The jumper member can accordingly be utilized to interconnect any two contact members 37 on plugboard 36.

FIGURES 12 and 13 show an embodiment of the contact assembly wherein each contact member 20, 30 has a base portion 4c, which is slightly longer than half the length of contact arms 50, 6c. Wing portions 5c and 6c extend from the contact arms, and the forward parts thereof are spaced from the forward part of base portion 4c so that, as shown in FIGURE 13, when the contact members and 3c are in engagement and the base portions 40 are abutting each other, the distance d bevveen base portion 40 of contact member and wing portion 6c of contact member 20 is the same for base portion of contact member 2c and wing portion 6c of contact member 3c. Thus, the distance d, between wing portions of contact members 20 and 3c, is greater than the distance d between wing portions 60 and the base portions 4c.

In FIGURE 14 there is shown a connector block similar to that shown and described in U. S. Patent No. 2,891,103, and reference numeral 38 denotes a female section and 39 is the male section thereof. Extending outwardly from diametrical sides of male section 39 are arms 40 integral therewith and extending from the rear portion toward the front portion. These arms are spaced from the central body portion but are so dimensioned (with reference to the physical properties, and particularly the stiffness of the material from which the block is made) that they can be flexed toward and away from the body portion. Arms 40 contain enlarged end portions 41 which taper toward the axis of the male portion of the block, and these enlarged end portions, in turn, define rearwardly facing shoulders 42 which advantageously extend normal to the axis of the block.

The remaining two sides of male portion 39 contain stop means 43 in the form of shoulders which extend transversely across the sides intermediate the ends of the block for the purpose of limiting the movement of this portion of the connector block relative to a panel P into which it is inserted. Rearwardly of stop 12, there is provided a flexible bracing means 44 which normally extends obliquely of the outer surface of the block and which, like arms 49, can be flexed toward and away from the body of the block. The position of flexible bracing means 44 relative to stop means 43 should be such that when the stop means is against panel P, the bracing means will be flexed in order to anchor the connector block relative thereto (see FIGURE 15).

A plurality of passageways 45 extend through the rear portion of male portion 39 and communicate with an enlarged chamber 46. Each passageway 45 has two channels 47 (see FIGURE 16) communicating therewith, as well as a recess 48 in the forward end thereof which also is in communication with chamber 46. At the inner end of channels 47 there is a stop 4 opposite recess 48.

Female section 38 has an end portion 5t dimensioned to fit relatively snugly over the end of male section 39, and preferably incorporates locking means 51 in the form of detents integral with the inner surface of end portion 56 which engage recesses 52 disposed on the outer surface of the front end of male section 39 when the connector block is assembled (see FIGURE 15). The wall thickness of female section 38 is such that it will fit between arms 40 and the body of male section 39 in order to prevent accidental disassembly from panel P. Internally, female section 38 is provided with passageways 53 axially aligned with passageways 45 which communicate with an enlarged chamber 54 in end portion 50. As in the male section, channels 47 communicate with passageways 53, as well as a recess 48 in the forward end thereof which is also in communication with chamber 54. Also, at the inner end of channels 47 there is a stop 49 opposite recess 48.

The assembly of the above-described connector block on panel P is obvious and need not be described; however, if a description is necessary, such can be readily found in U. S. Patent No. 2,891,103.

In each passageway 45 and 53, there is securely mounted the contact members 20 and 3;- shown in FIG- URES 12 and 13. I As can be seen, each wing portion 50, 6c is disposed in channels 47, and the forward end of each wing portion engages stop 49. A resilient tongue member 54, which can be stamped outwardly from the base portion 40 of each contact member as shown in contact member 3c of FIGURE 15, is disposed in recesses 48 of each passageway 45, 53, in order to maintain the contact members securely therein. Of course, tongue member 54 can be a resilient strip of metal secured onto the bottom surface of base portion 40 as by Welding. Other means for securing the contact members in their respective passageways can, of course, be provided but need not be enumerated herein.

In assembly, the contact members are placed in the passageways so that the wing portions thereof are disposed in channels 47. They are then pushed into the passageways until the forward ends of the wing portions engage steps 49, whereupon the resilient tongues become disposed in recesses 43 to thereby secure the contact members therein. Channels 47 prevent any lateral displacement of the contact members in the passageways.

It should be remembered that the channels 47 and recesses 48 of female section 38 are disposed at right angles with respect to the channels 47 and recesses 48 of male section 39 in order for the contact members to firmly and positively engage each other along substantially the entire length thereof as shown in FIGURES 12 and 13.

While the present invention has been described in conjunction with printed circuit boards and connector plugs, it is understood that the contact members can be made to any desirable size. 7

While the present invention has been described in conjunction with a number of different applications thereof, it is to be understood and appreciated that these are intended as merely representative and not as restrictive of the present invention, and that the present invention can be utilized in many other various applications falling within the purview of the present disclosure.

Having described my invention, 1 claim:

1. A contact assembly comprising complementary contact members each including a base portion, rigid arm members integrally connected to said base portion and extending substantialy parallel with respect to each other, said arm members having contact surfaces disposed opposite each other and extending along the entire length of said arm members, and spring means for resiliently biasing said arm members toward each other along a major bending axis parallel to the longitudinal axis of said contact member, the base portions of the contact members being normal with respect to each other and in abutting engagement and the contact surfaces of each contact member firmly and positively engaging one another along substantially the entire length of the arm members.

2. In a contact assembly, complementary contact members engaging each other at right angles with respect to one another, each contact member including arms extending substantially parallel with respect to each other and having contact surfaces disposed along the entire length thereof, a base portion connected to a portion of adjacent sides of said arms parallel with respect to the longitudinal axis of said arms, said contact surfaces extending along said base portion, and spring means normally biasing said arms toward each other parallel to the )ngitudinal axis to provide a firm and positive engage- 1ent between the complementary contact members.

3. A contact member comprising a pair of elongated, ubstantially parallel, spaced contact arms resiliently )ined at their sides only by an integral base member ridging the space between said arms and extending along portion of the length of said arms adjacent one end hereof, said arms, for substantially their entire length, icluding the portion along which said base member exends, being of uniform configuration and free for engag- Jg the corresponding arms of a like mating contact mem- 4. A contact member comprising contact arms having ontact-engaging surfaces along the length thereof and raving a uniform configuration therealong, an integral ase portion extending along sides of said contact arms rom one end of the contact arms to about the center hereof to resiliently maintain said contact arms substanially parallel and said contact-engaging surfaces opposed one another for engaging corresponding contact-engagng surfaces of a like contact member so that the contactngaging surfaces of each contact member extend along he base portions thereof.

5. A contact member for use with a complementary ontact member comprising a base portion, rigid arm nembers having corresponding sides integrally connected 0 said base portion and extending substantially parallel vith respect to each other, said base portion extending .long a portion of the length of said arm members, opvosed contact surfaces on said arm members extending long the entire length of said arm members and proided with a uniform configuration, and spring means in .ssociation with said base portion for maintaining said lI'IIl members spaced from each other and for resiliently :ngaging like contact arms of said complementary conact member along the entire lengths thereof and along he base portions thereof.

6. A contact member according to claim 5 wherein said trm members taper toward each other from the base porion to the free ends thereof.

7. A contact member according to claim 5 wherein :ach of said arm members includes a wing portion extendng outwardly from a side opposite to the side connected 0 thebase portion.

8. For use in a hermaphroditic contact assembly, a :ontact member comprising elongated contact arms dis- Josed in a substantially parallel manner and having conact surfaces opposing each other and extending the length )f the contact arms, a base portion integrally conlected to the contact arms and extending along a porion of the length thereof inwardly from the ends of he contact arms, said base portion maintaining said :ontact arms resiliently close together for engaging similar :ontact arms of a like contact member with the contact arms of both contact members being in engagement along heir length, along thebase portions thereof and with he base portions being disposed at an angular disposi ion with respect to each other.

9. In a contact member; contact arms having conact surfaces along the length thereof and opposite each )ther; a base portion extending integrally between said :ontact arms, outwardly from said contact surfaces and fesiliently maintaining said contact arms substantially Jarallel with respect to each other; said base portion :xtending along a portion of the length of said contact arms leaving ends of said contact arms to one end of said base portion free to engage similar contact arms of a like contact member so that the interengaging contact arms are in resilient engagement along their lengths and the free ends of the contact arms extend along corresponding base portions.

10. A contact member matable with a like contact member comprising a base portion, contact arms having one side integrally connected to said base portion from one end and along a portion of the length thereof, said contact arms from the inner end of said base portion to the other ends thereof being free, said base portion maintaining said contact arms substantially parallel and resiliently disposed, and contact surfaces on said contact arms having a substantially uniform configuration, being opposed to each other and extending the entire length of the contact arms and along the base portion.

11. In a contact member of the type described, contact arms having a substantially V-shape in cross-section and having contact surfaces extending along the entire length thereof, a base portion having sides thereof integrally connected to corresponding sides of said contact arms and extending along a portion of the length thereof to resiliently maintain said contact arms substantially parallel to each other with said contact surfaces being opposed with respect to each other and extending along said base portion, said contact arms from said base portion to one end thereof being free to engage corresponding contact arms of a like contact member.

12. A contact member comprising a base portion, rigid arm members having corresponding sides integrally connected to said base portion along a portion of the length from one end to about the center thereof and extending substantially parallel with respect to each other, said arm members having contact surfaces disposed opposite each other and extending along the length of said arm members and said base portion, and spring means in association with said base portion for resiliently maintaining said arm members spaced from each other along a major bending axis parallel to a longitudinal axis of said contact members and free for engaging corresponding arm members of a like contact member.

13. A contact member according to claim 12 wherein each of said arm members includes a minor bending axis normal to said major bending axis.

References Cited by the Examiner UNITED STATES PATENTS 2,266,530 12/41 Andren 339-258 X 2,335,843 11/43 Rogofi? 339-47 X 2,7 85,3 87 3 5 7 Batcheller. 3,054,979 9/62 Buiting 33949 3,070,769 12/62 Murphy 339-49 3,146,051 8/64 Woofter et al 339-49 X FOREIGN PATENTS 919,419 10/54 Germany. 1,011,030 6/57 Germany.

JOSEPH D. SEERS, Primary Examiner. 

3. A CONTACT MEMBER COMPRISING A PAIR OF ELONGATED, SUBSTANTIALLY PARALLEL, SPACED CONTACT ARMS RESILIENTLY JOINED AT THEIR SIDES ONLY BY AN INTEGRAL BASE MEMBER BRIDGING THE SPACE BETWEEN SAID ARMS AND EXTENDING ALONG A PORTION OF THE LENGTH OF SAID ARMS ADJACENT ONE END THEREOF, SAID ARMS, FOR SUBSTANTIALLY THEIR ENTIRE LENGTH, INCLUDING THE PORTION ALONG WHICH SAID BASE MEMBER EXTENDS, BEING OF UNIFORM CONFIGURATION AND FREE FOR ENGAGING THE CORRESPONDING ARMS OF A LIKE MATING CONTACT MEMBER. 